Aircraft galley chiller system

ABSTRACT

A galley chiller system for an aircraft includes at least one condenser having a refrigerant fluid. The fluid within the condenser rejects heat to a first surrounding environment. To more efficiently use the condenser of the galley chiller system and reduce the requirement on other cooling systems within an aircraft, the condenser may reject its heat to a desired location using a heat exchanger. The galley chiller system includes at least one evaporator that receives fluid from the condenser. A first evaporator absorbs heat from a galley, which may include a bank of carts. The first evaporator is arranged in ducting that carries cooled air to the carts. A second evaporator may absorb heat from a cabin recirculation air duct of the aircraft cooling system. In this manner, the evaporators of the inventive galley chilling system cools not only the galley carts but also provides supplemental cooling to the aircraft cooling system thereby reducing its cooling requirements.

This application is a Continuation-In-Part of U.S. application Ser. No.10/790,890 filed Mar. 2, 2004, which claimed priority to U.S.Provisional Patent Application Ser. No. 60/504,951 filed Sep. 22, 2003.

BACKGROUND OF THE INVENTION

The present invention relates to a galley chiller system for use in anaircraft, and more particularly, the invention relates to a moreefficient galley chiller system having components shared with othercooling systems of the aircraft.

A typical commercial aircraft includes at least several nonintegratedcooling systems. For example, an aircraft cooling system primarilyprovides cooling for the aircraft cabin area. A power electronicscooling system cools the power electronics of various aircraft systemsto maintain the electronics within a desired temperature range. A galleychiller system is dedicated to refrigerating the food carts in thegalleys located throughout the aircraft. Each of these systems have asignificant weight and power penalty associated to the aircraft. It isdesirable to minimize the overall weight and power penalty to theaircraft to increase the overall efficiency of the aircraft.

Typically galley chiller systems are stand alone vapor cycle units. Thegalley chiller system includes a compressor pumping a refrigerationfluid to a condenser, which rejects heat from the compressed fluidwithin to the surrounding environment. The fluid from the condenser isregulated through an expansion valve to an evaporator where therefrigerant fluid expands to cool the fluid. The refrigerant fluidwithin the evaporator absorbs heat from the surrounding environment. Therefrigerant fluid flows from the evaporator to the compressor where thecycle begins again.

The location of the galley chiller system condenser is such thattypically a portion of the heat from the condenser is rejected to thecabin area, which increases the load on the aircraft cooling system.When the galleys are cooled within the desired temperature range, thegalley chiller system may be unused or not operated to its full coolingcapacity resulting in inefficiency in the context of aircraft's overallcooling systems.

Therefore, what is needed is a more efficient galley chiller system thatmore effectively uses the condenser and evaporator to reduce therequirements on the other cooling systems of the aircraft resulting in areduction in weight and power penalty to the aircraft.

SUMMARY OF THE INVENTION

This invention provides a galley chiller system for an aircraft thatincludes at least one condenser having a refrigerant fluid. The fluidwithin the condenser rejects heat to a first surrounding environment. Tomore efficiently use the condenser of the galley chiller system andreduce the requirements on other cooling systems within an aircraft, thecondenser may reject its heat to a power electronics cooling system.Heat from the condenser may be used to heat a cargo area, or may simplybe rejected to ram air of an air conditioning pack of the aircraftcooling system or the exhaust air vent.

The galley chiller system also includes at least one evaporator thatreceives fluid from the condenser. In the embodiment shown, theinventive galley chiller system includes at least two evaporators. Afirst evaporator absorbs heat from a galley which may include a bank ofcarts. A second evaporator may absorb heat from a cabin upperrecirculation air duct of the aircraft cooling system. In this manner,the evaporators of the inventive galley chilling system cool not onlythe galley carts but also provides supplemental cooling to the aircraftcooling system thereby reducing its cooling requirements.

The cooling systems of the aircraft may also share some controls tomonitor and coordinate the operation of the cooling systems with oneanother. For example, a controller may be connected to a control valveof the recirculation evaporator to obtain a desirable proportion ofrefrigerant fluid through the evaporators to adjust the cooling capacityprovided to each of the galley carts and upper recirculation air duct.Remotely located heat exchangers may be connected to the condenser orevaporator using air or liquid cooling and arranged throughout theaircraft enabling the condenser to be packaged compactly with the othergalley chiller components while still providing heat to other aircraftareas.

Accordingly, this invention provides a more efficient galley chillersystem that more effectively uses the condenser and evaporator reducingthe requirements on the other cooling systems of the aircraft resultingin a reduction in weight and power penalty to the aircraft.

These and other features of the present invention can be best understoodfrom the following specification and drawings, the following of which isa brief description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional schematic view of a commercial aircraft.

FIG. 2 is a Venn diagram of cooling systems of an aircraft having theinventive galley chiller system.

FIG. 3 is a schematic view of one example of a galley chiller system.

FIG. 4 is a schematic view of another example inventive galley chillersystem.

FIG. 5 is a schematic view of a portion of the inventive galley chillersystem utilizing a heat exchanger in conjunction with the condensers.

FIG. 6 is a schematic view of another example galley chiller system forthe fore of the aircraft.

FIG. 7 is a schematic view of another example galley chiller system forthe aft of the aircraft.

FIG. 8 is still another example galley chiller system for the fore ofthe aircraft.

FIG. 9 is a schematic view of still another example galley chillersystem for the aft of the aircraft.

FIG. 10 is a schematic view of yet another example galley chiller systemfor both the fore and aft of the aircraft.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

A high level schematic cross-sectional view of a commercial aircraft 10is shown in FIG. 1. The aircraft 10 includes a cargo area 12 within thelower portion of the aircraft 10. The cargo area 12 may include one ormore power electronics power bays 14 housing various electroniccomponents used in the control and operation of the aircraft 10. Anaircraft cooling system 16 includes one or more air conditioning packstypically located within the cargo area 12. The aircraft cooling system16 provides temperature conditioned air to a cabin area 22 to provide acomfortable climate for the passengers within the cabin area 22. A powerelectronics cooling system 20 may also be located within the cargo area12 to cool the power electronics equipment bay 14.

Galleys 24 are positioned in various convenient locations within thecabin area 22. The galleys 24 house multiple galley carts containingfood and other perishable goods. The galleys 24 typically includeducting that delivers cooled air to the carts from a common air source.The galleys 24 and lavatories 26 vent odors to a vent system 30 locatedin an overhead area 28 located above the cabin area 22. Air from theflight deck, lavatories, galleys and other areas of the aircraft arepumped out the vent system 30 by a fan 39 through an outflow valve 32exhausting the air to the outside environment.

The inventive galley chiller system 36 is located in the overhead area28 in the examples shown, although the galley chiller system 36 orcomponents thereof may be located in any suitable area within theaircraft 10. The aircraft cooling system 16 includes ducting 37 havingan overhead recirculation air duct 38 located within the overhead area28, although the recirculation duct may be located elsewhere. The air isdelivered from the recirculation air duct 38 by recirculation fans 34.The aircraft cooling system 16 cools the air ducted to the cabin area22. To reduce the cooling requirement of the aircraft cooling system 16,the inventive galley chiller system 36 provides supplemental cooling tothe recirculation air when the cooling capacity of the galley chillersystem is not fully needed to cool the galleys 24. This improvedefficiency, and other improved efficiency of the cooling systems of theaircraft, is realized by integrating some of the components of thegalley chiller system with other aircraft cooling systems, which isrepresented by the Venn diagram of FIG. 2.

As very schematically depicted in FIG. 2, the galley chiller system 36includes a condenser 42, an evaporator 44, and controls 46. The galleychiller system 36 may also include ducting 37 for delivering the cooledair from the evaporator 44 or heated air from the condenser 42 to otheraircraft cooling systems. These galley chiller system components 36 maybe shared by other cooling systems of the aircraft, such as the aircraftcooling system 16 and the power electronics cooling system 20, whichwill be discussed in more detail below.

One example inventive galley chiller system 36 is shown in FIG. 3. Theschematic shown in FIG. 3 may be well suited for a forward locatedgalley cooler system, in addition to other galley locations within theaircraft 10. The galley cooling system 36 includes compressors 48 thatcompress and pump a refrigerant fluid to condensers 42 a and 42 b(collectively referred to as “42”), where heat from the compressed fluidwithin the condensers 42 is rejected to the surrounding environment. Therefrigerant fluid then flows to the evaporators 44 a and 44 b(collectively referred to as “44”) through expansion valves 50 a and 50b (collectively referred to as “50”). As the fluid exits the expansionvalves 50, the fluid expands lowering the temperature of the fluid. Theexpansion valves 50 control automatically to a desired superheatsetpoint. Preferably, the expansion valves 50 control to a superheat lowsetpoint of approximately between 5-10° F. to maximize cooling capacityfrom the evaporators 44 without liquid refrigerant slugging thecompressors 48.

Heat from the environment surrounding the evaporators 44 is absorbedinto the fluid prior to returning to the compressors 48. It may bedesirable to provide at least two condensers 42, evaporators 44 andcompressors 48 to provide redundancy within the galley chiller system36. Moreover, as will be appreciated from the discussion below, havingmultiple condensers 42 and evaporators 44 may better enable the galleychiller system 36 to be more efficiently integrated with other coolingsystems of the aircraft 10. Alternatively, it may be desirable toseparate the condensers 42 and evaporators 44 (FIGS. 8 and 9) to providea more manageable size and weight unit.

One evaporator 44 a may be arranged within the airflow path of theducting 37 of the galleys 24, which includes multiple galley carts 53.The air within the ducting 37 is moved through the galleys 24 by a fan52. The ducting 37 carries the air to one or more galleys 24, where itis distributed to each of the galley carts 53 by a manifold. At least aportion of the ducting 37 is preferably located in the area in which therest of the galley chiller system 36 is located, such as the overheadarea 28. Prior art arrangements require multiple heat exchanges to beconnected in a liquid cooling loop with the evaporator. Those heatexchangers are, in turn, arranged within separate ducting for eachgalley. One inventive arrangement enables a centrally located, commonevaporator to be used for multiple galleys and/or carts by placing theevaporator 44 a in the ducting 37. Of course, liquid loops may be usedto cool the galleys 24 (FIGS. 6 and 7). Furthermore, the liquid loopsmay be configured with the evaporators 44 b from the first and secondgalley chiller systems, shown at 100 and 102 in FIG. 10, in series.

The evaporator 44 a used to cool the galleys 24 may require a coolingcapacity sufficient to lower the temperature within the galley carts 53from approximately 40° F. to approximately 30° F. A second evaporator 44b may be arranged in the flow path of an upper recirculation air duct38. A fan 34 moves the air within the duct 38 across the evaporator 44b. The evaporator 44 b within the upper recirculation air duct 38 mayrequire a cooling capacity sufficient to cool the air from approximately100° F. to approximately 50° F.

The cooling system controls 46 includes a controller 56 that is directedto a recirculation evaporator control valve 51. The control valve 51meters the flow of refrigerant fluid into the evaporators. The amount offluid entering the evaporators corresponds with the cooling capacity forthe evaporator. That is, generally, the more refrigerant fluid enteringevaporator, the more cooling capacity that is provided by thatevaporator. The valve 51 maintains to a minimum pressure to precludeair-side freezing.

The controller 56 coordinates the operation of the control valve 51based upon, for example, a temperature sensor 54 associated within thegalleys 24. The speed of the galley fan 52 is controlled to obtain therequired temperature at the galley outlet temperature sensor 54. Thetemperature sensor 59 measures the temperature at the inlet of thegalley 24 or galley carts 53, and the controller 56 determines theamount of refrigerant fluid necessary to flow into the evaporator 44 aassociated with the galley 24 to ensure that the air is cooled to thedesired temperature.

When the air in the galleys 24 is cooled to the desired temperature, thecontroller 56 may open the control valve 51 associated with therecirculation air evaporator 44 b and supplement the cooling of theupper recirculation air provided by the aircraft cooling system 16.Additionally, the valve 55 is used to provide defrost capability for theevaporators 44 a and 44 b.

With continuing reference to FIG. 3, the condensers 42 reject heat todesired areas of the aircraft 10 to reduce the requirements on othercooling systems of the aircraft. To obtain a more compact galley chillersystem 36 and keep the condensers 42 in close proximity to the othergalley chiller system components, one or more heat exchangers may belocated remotely from the galley chiller system and connected to thecondensers by a liquid cooling passage extending in a loop between theheat exchanger and condensers 42.

In one example shown in FIG. 3, a pump 58 pumps a cooling liquid fromthe condenser 42 a to a cargo heat exchanger 60 located within the cargoarea 12. Another heat exchanger 62 may be located within the same loopand integrated as part of the power electronics cooling system 20 toreject heat to the aircraft exterior through the RAM system. In anotherexample shown in FIG. 3, another pump 58 may pump a cooling liquid fromthe condenser 42 b to another cargo heat exchanger 60. Another heatexchanger 64 within the same loop may be located within a ram airflowpath of an air conditioning pack 18 to reject the hot air to theaircraft exterior.

Another example galley chiller system 36 is shown in FIG. 4, which maybe suitable for an aft galley chiller system 36 or any other suitablegalley location. The operation of the galley chiller system 36 as shownin FIG. 4 is similar to that shown in FIG. 3. However, the condensers 42a and 42 b are positioned within the vent system 30 to reject heat tothe exhaust air within the vent, which exits the aircraft 10 through theoutflow valve 32. To obtain a more compact galley chiller system 36 andkeep the condensers 42 in close proximity to the other galley chillersystem components, an exhaust air heat exchanger may be located remotelyfrom the galley chiller system and connected to the condensers by aliquid cooling passage 71 extending in a loop between the heat exchangerand condensers 42. For example, FIG. 5 illustrates a heat exchanger 70,which carries liquid heated by the condensers 42, arranged in the ventsystem 30 to reject heat to the air driven by the fan 39 out the outflowvalve 32.

FIGS. 6 and 7 are similar to FIGS. 3 and 4, however, FIGS. 6 and 7utilize a liquid loop 80 to cool the galleys 24.

Referring to FIG. 6, a liquid condenser loop 71 is used to coolcomponents remote from the condensers 42, such as power electronics. Asimilar loop is shown in FIGS. 4 and 5.

A flash tank 76 is used to increase the cycle efficiency and reduce thecompressor power requirement by up to 20%. The flash tank 76 receivesslightly subcooled liquid exiting the condenser 42 through a fixedorifice to throttle the fluid from the condenser 42 to an interstagepressure or midlevel stage of the scroll-type compressor. The throttledliquid from the flash tank 76 flows through a pressure regulator 78 tothe compressor 48. Liquid from the flash tank 76 flows through thethermostatic expansion valve 50 to the evaporator 44.

A liquid loop 80 is used in connection with the evaporators 44 to coolthe galleys 24. A liquid heat exchangers 86 may be associated with eachof the galleys and arranged within the galley ducting 37. A fan 52 blowsair through the liquid heat exchanger 86 to cool the galleys 24.Diverter valves 84 may be arranged in the liquid loop 80 to direct theflow of fluid through the liquid loop 80 to as desired based upon thecooling needs of each of the galleys 24.

An aft galley chiller system is shown in FIG. 7. The aft galley chillersystem of FIG. 7 is similar to that shown in FIG. 4, however, the galleychiller system 36 includes the liquid loop 80 shown in FIG. 6.

1 Referring to FIGS. 8 and 9, the galley chiller systems 36 shown aresimilar to those depicted in FIGS. 3 and 4, however, the systems 36 canbe divided to provide first and second galley refrigeration units 90 and92.

The galley chiller systems 36 depicted in FIGS. 3 and 4 includecondensers 42 a and 42 b and evaporators 44 a and 44 b that arephysically combined with one another in one location. The systems shownin FIGS. 3 and 4 provide redundancy within the galley chiller system 36,but results in a bulky, heavy package. As an alternate approach, thegalley chiller system 36 may be split into the first and second galleyrefrigeration units 90 and 92, as schematically depicted by thepartition line 94. As a result, each galley refrigeration unit 90 and 92is approximately half the weight of the system shown in FIGS. 3 and 4,which makes installation and removal of the systems easier. Accordingly,each of the evaporators 44 a and 44 b are arranged within separaterecirculation air ducting 38 a and 38 b. The evaporators 44 a and 44 bare also associated with separate galley ducting 37 a and 37 b.

1 Referring to FIG. 10, first and second galley chiller systems 100 and102 are shown. For the example shown, the first and second galleychiller systems 100 and 102 are located in the aft of the aircraft,although they serve both fore and aft galleys. The systems 100 and 102each include an air cooling galley circuit 104 for cooling first galley106. The liquid galley cooling circuit 108 cools second galleys 110.However, the liquid heat exchanger 86 of the first and second galleychiller systems 100 and 102 form a series connection providing a liquidgalley cooling circuit 108. Controls (not shown) cooperate with theseries, liquid galley cooling circuit 108 to regulate the flow of liquidto the heat exchangers 86 since there is a heat build-up within theseries circuit 108 as the fluid progresses through the circuit 108.Aside from the series liquid galley cooling circuit 108, the liquidcooling circuit 108 is arranged similarly to that shown in FIGS. 6 and7.

Although a preferred embodiment of this invention has been disclosed, aworker of ordinary skill in this art would recognize that certainmodifications would come within the scope of this invention. For thatreason, the following claims should be studied to determine the truescope and content of this invention.

1. A galley chiller system for an aircraft comprising: at least onecondenser having a fluid, said fluid in said at least one condenserrejecting heat to a first surrounding environment; and at least oneevaporator receiving said fluid from at least one condenser, said fluidin said evaporator absorbing heat from a second surrounding environmentincluding a galley cart and a third surrounding environment including anair duct of an aircraft cooling system.
 2. The galley chiller systemaccording to claim 1, comprising a first evaporator absorbing heat fromsaid second surrounding environment, and a second evaporator absorbingheat from said third surrounding environment.
 3. The galley chillersystem according to claim 1, wherein said air duct is a cabinrecirculation air duct.
 4. The galley chiller system according to claim1, wherein said galley chiller system includes at least two evaporators,at least two condensers, and at least one compressor, said condensersfluidly connected to each of said evaporators and said at least onecompressor fluidly connected to said condensers.
 5. The galley chillersystem according to claim 4, wherein said galley chiller system includesfirst and second galley refrigerant units respectively including one ofsaid at least two evaporators and condensers and another of said atleast two evaporators and condensers.
 6. The galley chiller systemaccording to claim 5, wherein a liquid cooling loop is provided betweensaid at least two evaporators and at least two galley heat exchangers.7. The galley chiller system according to claim 6, wherein said at leasttwo evaporators and said at least two galley heat exchangers areconnected in series.
 8. The galley chiller system according to claim 6,wherein a recirculation air heat exchanger is connected to said liquidcooling loop, said recirculation heat exchanger arranged in arecirculation air duct.
 9. The galley chiller system according to claim1, comprising a heat exchanger arranged in a galley duct, said heatexchanger including a liquid cooling loop between said heat exchangerand said evaporator, said liquid cooling at least partially definingsaid third surrounding environment.
 10. The galley chiller systemaccording to claim 9, wherein the air duct is a cabin recirculation airduct.
 11. A galley chiller system for an aircraft comprising: at leastone condenser having a fluid, said fluid in said at least one condenserrejecting heat to a first surrounding environment; at least oneevaporator receiving said fluid from at least one condenser, said fluidin said evaporator absorbing heat from a second surrounding environment;and ducting defining at least a portion of said second surroundingenvironment, said ducting carrying cooled air in said ducting to agalley cart.
 12. The galley chiller system according to claim 11,comprising a galley having multiple galley carts, said ducting carryingsaid cooled air to said multiple galley carts.
 13. The galley chillersystem according to claim 12, comprising multiple galleys with saidducting carrying said cooled air to said multiple galleys.
 14. Thegalley chiller system according to claim 13, comprising multiple liquidheat exchangers associated with said multiple galleys, said multipleliquid heat exchangers connecting in a liquid cooling loop with said atleast one evaporator.
 15. The galley chiller system according to claim14, wherein said liquid loop includes a recirculation air heat exchangerarranged in a recirculation air duct.
 16. The galley chiller systemaccording to claim 14, wherein said multiple liquid heat exchangers andsaid at least one evaporators are connected in series.